Return pad cable connector

ABSTRACT

A return pad cable connector, in accordance with the present disclosure, for use with a disposable return pad, includes a cord having a conductive wire disposed therethrough which conductive wire interconnects the return pad cable connector to an electrosurgical energy source. The return pad clamp further includes a connector operatively coupled to the cord, the connector having a conductive surface which is selectively engageable with a corresponding conductive surface disposed on the return pad, the conductive surface of the connector including a conductive adhesive disposed thereon and a non-conductive adhesive disposed above the periphery of the conductive surface of the connector for engagement with a corresponding non-conductive adhesive disposed above the periphery of the conductive surface of the return pad. The connector can include a magnet for magnetically coupling the connector to the conductive surface disposed on the return pad.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation-in-Part of InternationalApplication Ser. No. PCT/US02/17360, filed May 31, 2002 which claimspriority to U.S. Provisional Patent Application Ser. No. 60/295,176,filed Jun. 1, 2001.

BACKGROUND

1. Technical Field

The present disclosure relates to a return pad cable connector and, moreparticularly, to a return pad cable connector having a reusable cableconfiguration and adapted to removably receive a disposable single usepatient return pad.

2. Background of Related Art

Flexible conductive members (i.e., return pads, return electrodes, etc.)are of particular importance in the medical community wherein patientsoften need to be connected to electrical monitoring or electricalgenerating equipment. In such applications, flexible conductive memberssuch as return pads or electrodes need to adapt to the shape of thepatient's body in order to provide sufficient electrical contact withthe surface of the patient's body.

Electrosurgery requires that an electrosurgical generator be connectedto at least two electrodes to produce and deliver an electricalpotential to a patient's body. For example, in monopolar electrosurgery,the electrodes usually consist of an active electrode applied at thesurgical site and a return electrode or pad applied to a non-surgicalsite on the patient.

Generally, return electrodes are pliable and thus can be flexed orshaped to meet particular application requirements. Return electrodesare usually manufactured to attach with a pressure sensitive adhesivedirectly to the surface of the patient's body. Return electrodes aretherefore designed and manufactured to be form fitting or flexible so asto provide adequate conductive contact with the non-flat surfaces of apatient's body. Typically a conductive adhesive is applied to thesurface of the return electrode to hold and secure the return electrodeto the patient's body.

The return electrodes need to be electrically connected to the sourceelectrosurgical generator. This connection is usually provided by way ofone or more insulated conductive wires which are configured to interfacewith the electrosurgical generator to complete the electrosurgicalcircuit. In the past, emphasis was placed on providing a tight physicalconnection between the conductive wire and the return electrode whichcould withstand potential disengagement of the conductive wire andreturn pad during a surgical procedure.

Contemporary wire termination and connection methods usually requirethat the ends of a wire be stripped of insulation, formed, and assembledto the flexible conductive member with a staple shaped attachment orsome other attachable fastener such as a circular terminal and a rivet.The stripping process is highly dependent upon the nature of theinsulation of the wire, the strip tooling design, and the tooling setup.Wire stripping problems can result in broken wire strands or wires thatcannot be formed or terminated properly in subsequent operations. As canbe appreciated, existing terminating and connection manufacturingprocesses tend to be overly complex and typically require tediousmanufacturing steps to assure adequate electrical and mechanicalconnections. Inadequate electrical connections can result in impedancechanges across the tissue which may effect the performance of theoverall electrosurgical system.

In addition, for sanitary and medical reasons, after a return electrode(i.e., return pad) has been used in a medical procedure for a particularpatient, the return pad is discarded and a new return pad is used for anew medical procedure for either the same or a different patient. Sincereturn pads of the prior art are usually physically coupled to theconductive wire (i.e., hard wired), the conductive portion andgeneration leads are discarded along with the return pad. Typically,only the return pad needs to be discarded after each medical procedurefor sanitary reasons. Disposal of both the return pad and the conductiveportion simply increases the costs associated with the medicalprocedure.

Accordingly, the need exists for a return pad/electrode cable connectorwhich incorporates a disposable return pad which is removably coupled toa reusable conductive portion/connector.

SUMMARY

A return pad cable connector, in accordance with the present disclosure,for use with a disposable return pad, includes a cord having aconductive wire disposed therethrough which conductive wireinterconnects the return pad cable connector to an electrosurgicalenergy source. The return pad further includes a connector operativelycoupled to the cord, the connector having a conductive surface which isselectively engageable with a corresponding conductive surface disposedon the return pad, the conductive surface of the connector including aconductive adhesive disposed thereon and a non-conductive adhesivedisposed above the periphery of the conductive surface of the connectorfor engagement with a corresponding non-conductive adhesive disposedabove the periphery of the conductive surface of the return pad.

A return pad cable connector, in accordance with a further embodiment ofthe present disclosure, for use with a disposable return pad, includes acord having a conductive wire disposed therethrough which conductivewire interconnects the return pad cable connector to an electrosurgicalenergy source and a connector operatively coupled to the cord.Preferably, an adhesive is provided on the connector, the return pad oron both. The connector includes at least one conductive surface whichcorrespondingly mates with at least one conductive surface on the returnpad. The conductive surface of the connector includes a bordertherearound for engaging a border around the conductive surface of thereturn pad. The adhesive is provided on the conductive surface of theconnector, the conductive surface of the return pad, the bordersurrounding the conductive surface of the connector and/or the bordersurrounding the conductive surface of the return pad. Preferably, atleast the adhesive provided on the conductive surface of the return padis a conductive adhesive.

In still yet another embodiment, according to the present disclosure thecord-to-pad connector includes a base element having a handle and afixed jaw having a conductive surface affixed to an inner surfacethereof. A distal end of the conductive wire passes through the baseelement and operatively engages the conductive surface of the fixed jaw.The cord-to-pad connector further includes a return pad clamp pivotallymounted to the base element. The cord-to-pad connector is positionablebetween an open position wherein the return pad clamp is spaced from thefixed jaw and a closed position wherein the return pad clamp is incontact with the fixed jaw. Preferably, the return pad clamp includes amoveable jaw and a clamping lever depending therefrom and extendingalong the handle which allows a user to selectively engage and disengagea return pad.

Preferably, the cord-to-pad connector further includes a lockingmechanism configured and adapted to selectively maintain the cord-to-padconnector in the closed position. The locking mechanism includes a latchprojecting from the clamping lever of the return pad clamp and a lockingrail projecting from a locking aperture formed in the handle. In use,the latch operatively engages the locking rail, thereby locking thecord-to-pad connector in the closed position.

Preferably, the return pad includes a pad-to-cord connector which has aconductive pad surface disposed thereon which conductive pad surface isconfigured and adapted to operatively engage the conductive surface ofthe base element. In this manner, an electrical connection between thereturn pad and the cord-to-pad connector is established.

In an alternative embodiment, the return pad cable connector of thepresent disclosure includes a cord having a conductive wire disposedtherethrough which connects to an electrosurgical energy source and aconnector which operatively couples to the cord wherein the connectorhas at least one magnet disposed thereon for magnetically coupling theconnector to a conductive surface disposed on the return pad. Inaccordance with the present disclosure, when the connector ismagnetically coupled to the conductive surface disposed on the returnpad energy is permitted to pass from the return pad to theelectrosurgical energy source via the conductive wire.

Preferably, the at least one magnet is made from an electricallyconductive material. More preferably, the conductive wire of the cord iselectrically coupled to the at least one electrically conductive magnet.

In an alternative embodiment, the connector further includes at leastone electrical contact disposed on the surface of at least one of themagnets. Preferably, the conductive wire of the cord is electricallycoupled to each of the at least one electrical contacts.

In still an alternative embodiment, the connector includes a flexiblesubstrate having a first portion and a second portion integrallyconnected to the first portion, the first and second portion defining afold line therebetween and a magnet disposed on each of the first andsecond portions of the flexible substrate in order to sandwich theconductive surface of the return pad therebetween. Preferably, theconductive wire of the cord is electrically coupled to the magnet, suchthat when the connector is magnetically coupled to the conductivesurface disposed on the return pad, energy is permitted to pass from thereturn pad to the electrosurgical energy source via the conductive wire.

It is envisioned that at least the magnet which is electrically coupledto the conductive wire is made from an electrically conductive material.Preferably, the connector further includes at least one electricalcontact disposed on the surface of the magnet which is electricallycoupled to the conductive wire. The conductive wire of the cord ispreferably electrically coupled to each of the at least one electricalcontacts.

It is envisioned that the conductive wire of the cord can extend from aside of the substrate which is either parallel to the fold line ortransverse to the fold line. It is further envisioned that each magnetis coupled to the substrate via a pin passing through the magnet andinto the substrate.

These and other advantages and features of the apparatus disclosedherein, will become apparent through reference to the followingdescription of embodiments, the accompanying drawings and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above, andthe description of the embodiments given below, serve to explain theprinciples of the invention.

FIG. 1 is a bottom plan view of a return pad and an electrode cableconnector in accordance with the present disclosure;

FIG. 2 is a perspective view of a return pad and an electrode cableconnector in accordance with an alternative embodiment of the presentdisclosure;

FIG. 3 is a perspective view of a return pad and an electrode cableconnector in accordance with yet another embodiment of the presentdisclosure;

FIG. 4 is an exploded, perspective view of a return pad and an electrodecable connector similar to the embodiments shown in FIG. 3;

FIG. 5 is a cross-sectional side elevational view of the electrodeconnector of FIG. 4 shown in the closed position;

FIG. 6 is a cross-sectional side elevational view of the electrodeconnector of FIG. 4 shown in the open position;

FIG. 7 is a top plan view of an electrode cable connector in accordancewith an alternative embodiment of the present disclosure;

FIG. 8 is a top plan view of an electrode cable connector in accordancewith yet another embodiment of the present disclosure;

FIG. 9 is a perspective view of an electrode cable connector inaccordance with still another embodiment of the present disclosure; and

FIG. 10 is a side elevational view of an electrode cable connector ofFIG. 9 illustrating a preferred method of coupling of a magnet to asubstrate thereof.

DETAILED DESCRIPTION

Preferred embodiments of the presently disclosed return pad cableconnector will now be described in detail with reference to the drawingfigures wherein like reference numerals identify similar or identicalelements.

Referring now in detail to FIG. 1, a return pad cable connector is shownin accordance with the present disclosure and is generally identified as100. Cable connector 100 includes a reusable conductive wire cable 102which operatively couples at a proximal end thereof to anelectrosurgical generator “E/S” and a reusable cord-to-pad interface 104which is disposed at a distal end thereof. Cord-to-pad interface 104includes an insulated backing 106 having a conductive cord surface 108disposed thereon which electrically couples to a wire 107 passingthrough cable 102.

An adhesive border 110 is defined about the outer periphery of theconductive cord surface 108. It is contemplated that conductive cordsurface 108 may be positioned along one edge of cord-to-pad interface104 to facilitate connection with the return pad 120. However, it isalso envisioned that the conductive cord surface 108 or multipleconductive cord surfaces 108 may be arranged anywhere on the surface ofthe cord-to-pad interface 104 depending upon a particular purpose or tofacilitate electrical engagement. Preferably, the adhesive border 110includes a non-conductive adhesive 112 applied thereto which reducesstray electrical current from emanating from the conductive cord surface108. While application of non-conductive adhesive 112 to adhesive border110 is preferred, it is envisioned that adhesive border 110 may standalone without adding the non-conductive adhesive 112.

As seen in FIG. 1, cable connector 100 is configured and adapted to beremovably adhered to a return pad or return electrode 120. Return pad120 includes an insulated backing 122, an insulated cover 124 and aconventional electrically conductive member 126 retained betweeninsulated backing 122 and insulated cover 124.

Insulated backing 122 includes a pad-to-cord interface 128 which extendsfrom a side surface thereof. Pad-to-cord interface 128 includes aconductive pad surface 130, preferably made from an electricallyconductive material, disposed thereon which electrically couples returnpad 120 to the conductive cord surface 108. Conductive pad surface 130is electrically connected to conductive member 126 (via at least oneconductive wire 132 which is disposed between backing 122 and cover124). An adhesive border 134 is defined about the outer periphery of theconductive pad surface 130. It is contemplated that conductive padsurface 130 is positioned to compliment the particular arrangements ofconductive surface(s) 108 on the cord-to-pad interfaces. Much likeadhesive border 110, adhesive border 134 may also include anon-conductive adhesive 112 applied thereto to facilitate engagement andreduce stray electrical currents.

While application of non-conductive adhesive 112 to adhesive border 134of pad-to-cord interface 128 is preferred, the non-conductive adhesive112 need not be applied to adhesive border 134 especially if thenon-conductive adhesive 112 is provided on adhesive border 110 ofcord-to-pad interface 104. It is further envisioned, that if thenon-conductive adhesive 112 is provided on return pad 120 along adhesiveborder 134 of pad-to-cord interface 128, no adhesive, either conductiveor non-conductive, need be provided on adhesive border 110 ofcord-to-pad interface 104.

A non-conductive adhesive for adhering adhesive border 110 ofcord-to-pad interface 104 to adhesive border 134 of pad-to-cordinterface 128 is disclosed in commonly owned U.S. Pat. No. 4,699,146 toSieverding, the entire contents of which are incorporated herein byreference. By providing cord-to-pad interface 104 with an adhesiveborder 110 and providing pad-to-cord interface 128 with an adhesiveborder 134, sufficient electrical connection is established betweenconductive cord surface 108 and conductive pad surface 130. Moreparticularly, cord-to-pad interface 104 is adhered to pad-to-cordinterface 128 by applying the non-conductive adhesive 112 to theirrespective adhesive borders 110 and 134 and pressing the two interfacestogether. In this manner, conductive cord surface 108 directly contactsconductive pad surface 130 thereby establishing an electrical connectiontherebetween.

Turning now to FIG. 2, a return pad cable connector is shown inaccordance with another embodiment of the present disclosure and isgenerally identified as cable connector 200. Cable connector 200includes a reusable conductive wire cable 202 having a typical connector204 attached to a proximal end thereof for interfacing cable 202 with anelectrosurgical generator (not shown) and a reusable cord-to-padinterface 206 operatively coupled to a distal end thereof. Cord-to-padinterface 206 includes an insulated backing 208 having a pair ofconductive cord surfaces 210 a, 210 b disposed thereon whichelectrically couple to a wire 212 passing through cable 202.

Conductive cord surfaces 210 a, 210 b are preferably spaced from oneanother and extend distally along a top surface 211 of cord-to-padinterface 206. An adhesive border 214 is defined about the periphery ofeach conductive cord surface 210 a, 210 b. Adhesive border 214 mayinclude a non-conductive adhesive 216 applied thereto in order tofacilitate mechanical connection with return pad 220. A conductiveadhesive 218 a, 218 b is applied to each conductive cord surface 210 a,210 b, respectively.

As seen in FIG. 2, cable connector 200 is configured and adapted to beremovably adhered to return pad 220. Return pad 220 is similar to returnpad 120 of FIG. 1 but includes a pair of complimentary conductivesurfaces 230 a, 230 b which electrically couple with conductive padsurfaces 210 a, 210 b, respectively. Each conductive surface 230 a, 230b, in turn, is coupled to a conductive member 236 a, 236 b disposedwithin the return pad 220.

More particularly, return pad 220 includes an insulated backing 222having a pad-to-cord interface 228 which extends from a side surfacethereof. Pad-to-cord interface 228 includes the pad conductive surfaces230 a, 230 b disposed thereon which couple with conductive cord surfaces210 a, 210 b. An adhesive border 234 surrounds the periphery of eachconductive pad surface 230. Adhesive border 234 is configured to includea non-conductive adhesive 216 applied thereto which reduces straycurrent which may emanate from the conductive surfaces. A conductiveadhesive 218 and covers each conductive pad surface 230 a, 230 b tofacilitate and maintain electrical connection with conductive cordsurfaces 210 a, 210 b.

Preferably, a conductive adhesive 218 is selected such that theconductivity of the adhesive will be sufficient for the electrosurgicalpower to be conducted through the small area of the attachment as wellas provide impedance low enough for contact quality monitoring in thegenerator. While a non-conductive and a conductive adhesive have beencontemplated for use in the present embodiment, it is envisioned that asingle conductive adhesive can be applied to both adhesive borders 214and 234 as well as to both conductive surfaces 210 a, 210 b and 230 a,230 b. Adhesive 218 a, 218 b is selected such that theelectro-conductivity of the adhesive promotes the transfer of electricsignals between conductive surfaces 210 a, 210 b and 230 a, 230 b.

It is envisioned that a non-conductive or conductive adhesive may onlybe applied to conductive surface 210 a, 210 b, 230 a and 230 b or,alternatively, a non-conductive or a conductive adhesive may only beapplied to adhesive borders 214, 234. It is further envisioned thatadhesive does not have to be provided on conductive surfaces 210 a, 210b, 230 a or 230 b and an adhesive may be solely applied to one of theadhesive borders 214, 234, preferably adhesive border 234 of return pad220.

Turning now to FIGS. 3-6, a return pad cable connector is shown inaccordance with another embodiment of the present disclosure and isgenerally identified as 300. Cable connector 300 includes two majorsubunits; a base element 302 and a return pad clamp 304 (see FIG. 4). Asexplained in greater detail below, base element 302 and return pad clamp304 cooperate to grip the return pad 400. It is contemplated that bothbase element 302 and return pad clamp 304 are preferably molded from astrong, resilient plastic material, such as acetal resin.

Base element 302 includes a return pad interface 306 and a handle 308.Preferably, handle 308 is dimensioned to facilitate gripping and may beergonomically shaped to enhance “feel”.

Return pad interface 306 preferably includes a fixed jaw 312 having anL-shaped cross-section defined by a first leg 310 for housing a seriesof pivot mounts 336 disposed therein and a second leg 311 whichvertically extends therefrom which cooperates with the pad clamp 304 tosecure the return pad 400 as explained in more detail below. A leverhousing 314 is formed in the pad interface 306 and operates tomechanically align and secure the pad clamp 304 with handle 308. Moreparticularly, a locking aperture 316 extends through handle 308 and islocated toward the distal end of the same (308). As explained in moredetail below, locking aperture 316 and lever housing 314 cooperate toalign and secure the pad clamp 304 within handle 308.

Return pad clamp 304 includes a movable jaw 318 and a clamping lever 320which depends from movable jaw 318 and which is designed to mechanicallyengage handle 308. Clamping lever 320 includes a proximal half 322having an offset 324 which extends at an angle relative to proximal half322. A distal half 326 depends from offset 324 such that proximal half322, offset 324 and distal half 326 form a generally reverse “S”configuration which facilitates assembly of the cable connector 300. Inother words, the proximal and distal halves 322 and 326 are generallyparallel to one another and offset 324 is disposed perpendicularthereto. Movable jaw 318 also includes a series of pivot projections 334which are designed for mechanical engagement with pivot mounts 336 asdiscussed below.

A locking pivot grip 328 is disposed on the proximal half 322 of thereturn pad clamp 304 and a corresponding unlocking pivot grip 330 isformed on the distal half 326. The locking and unlocking pivot grips 328and 330 are designed to facilitate movement of clamping lever 320 by anoperator's finger to mechanically move/pivot jaw member 318 from a firstopen position for reception of the return pad 400 to the second lockingposition which secures the return pad 400 in electromechanicalengagement with the cable connector 300.

Return pad clamp 304 is pivotally mounted to base element 302 so thatmovable jaw 318 lies in registration with fixed jaw 312 and pivots aboutan axis “A” (see FIGS. 5 and 6) defined through first leg 310 of thereturn pad interface 306. More particularly, the return pad clamp 304 ismounted by passing clamping lever 320 through lever housing 314 andengaging the pivot projections 334 within the corresponding pivot mounts336 disposed in first leg 310.

Clamping lever 320 when mounted extends along handle 308, preferablylying in a channel 338 defined therein. More particularly, clampinglever 320, when mounted, extends through lever housing 314 and tolocking aperture 316 such that the distal half 326 is movable withinlocking aperture 316 from a first locking position wherein movable jawis secured tot he return pad 400 (see FIG. 5) to a second open positionfor disengaging the return pad 400 (see FIG. 6). Preferably, lockingaperture 316 is designed to accept and cooperate with clamping lever 320in the manner described above. For example, in one embodiment, lockingaperture 316 is generally keyhole shaped, with a rectangular portiondesigned to accommodate distal half 326 of clamping lever 320, and acircular, chamfered thumb well 340 which surrounds un-locking grip 330.The length of offset 324 is preferably dimensioned to allow proximalhalf 322 to lie generally flush with the outer surface of handle 308when clamping lever 320 is disposed in the “locked” position. Also, whenlocked, distal half 326 is generally flush with the opposite surface ofhandle 308.

A locking rail 342 is disposed within locking aperture 316 and isdesigned to mechanically engage a corresponding latch 332 disposed onoffset 324 to secure clamping lever 320 in a “locked” position which, inturn, locks the cable connector 300 to the return pad 400. As can beappreciated, cooperation between locking rail 342 and latch 332 is madepossible by dimensioning clamping lever 320 such that the distance fromaxis A to the tip of latch 332 is slightly less than the distance fromthat point to the tip of locking rail 342. Thus, when the unit is in alocked position, as shown in FIG. 5, latch 332 is securely retained bylocking rail 342. As described in more detail below, movement of distalhalf 326 via un-locking grip 330 in direction “D” disengages latch 332from locking rail 342 which, in turn, disengages/unlocks the clampinglever 320 and releases the return pad 400.

As best shown in FIG. 4, base element 302 also includes a conductivesurface 344 affixed to an inner facing surface of fixed jaw 312 whichcouples with a conductive wire 346 extending from handle 308 to theelectrosurgical generator (not shown).

Returning to FIG. 3, cable connector 300 is configured and adapted to beremovably coupled to return pad 400. Return pad 400 includes aninsulated backing 402, an insulated cover 404 and a conventionalelectrically conductive member 406 retained between insulated backing402 and insulated cover 404.

Insulated backing 402 includes a pad-to-cord connector 408 extendingfrom a side surface thereof. Pad-to-cord connector 408 includes aconductive pad surface 410 disposed thereon for electrically connectingreturn pad 400 to conductive surface 344 of connector 300. Conductivepad surface 410 is electrically connected to conductive member 406 via aconductive path 412. An adhesive border 414 surrounds conductive padsurface 410 and is configured such that a non-conductive adhesive 416can be applied thereto. It is contemplated that a conductive adhesivecan be applied between conductive surface 344 of connector 300 and padconductive surface 410 to assure electrical continuity between the same.

As seen in FIG. 5, while in a locked position connector 300 firmly holdsreturn pad 400 between fixed and movable jaws 312 and 318, respectively,via the mechanically cooperative action of latch 332 and locking rail342. In this manner, conductive surface 344 of connector 300 andconductive pad surface 410 of return pad 400 are held in electricalcontact with one another. In the open position, as shown in FIG.6,movable jaw 318 is rotated away from fixed jaw 312, permitting insertionand removal of return pad 400 therefrom.

Movement between the open and the closed/locked positions is shown inFIGS. 5 and 6. To move from the closed/locked position (as seen in FIG.5), the operator applies a force in the direction “D” to unlocking grip330, preferably by pressing with a thumb or finger. By applying a forcein the direction “D” the distal half 326 and latch 332 unlocks causingthe movable jaw 318 of clamping member 320 to pivot away from fixed jaw312 and release pad 400. In turn, offset 324 rotates upward, forcing theproximal half 322 out of channel 338. More particularly, applying aforce in the direction “D” rotates the pivot projections 334 withinpivot mounts 336 to cause movable jaw 318 to open. Once rotated to the“open” position, the return pad 400 is either released or a new returnpad may be positioned therein.

Once the return pad 400 is in place between the movable jaw 318 and thefixed jaw 312, the connector 300 can be locked. Locking of connector 300involves applying a force in a direction “C” to locking grip 328. Thisforces latch 332 against locking rail 342, causing proximate leg 322 toflex and rotate latch 332 beyond locking rail 342 thus moving clamplever 320 to a “locked” position (see FIG.5). In turn, the pivotprojections of moveable jaw 318 are rotated within pivot mounts 336 offixed jaw 316 thereby securing return pad 400 between the jaw members312, 318.

In accordance with the present disclosure, it is envisioned that eachjaw member 312, 318 may be provided with a plurality of teeth 317 formedon either conductive surface 344 of connector 300, the non-conductivesurface of second leg 311 of fixed jaw 312 or both. Accordingly, theplurality of teeth 317 increases the retention of pad-to-chord connector408 of return pad 400 therebetween.

Turning now to FIGS. 7-10 a return pad cable connector in shown inaccordance with the principles of the present disclosure and isgenerally identified as 500. In accordance with the present disclosureit is envisioned that return pad cable connector 500 is configured andadapted to cooperate with a return electrode 120 as generally describedabove.

With particular reference to FIG. 7, return pad cable connector 500includes a conductive return wire cable 502, operatively coupled at aproximal end thereof to an electrosurgical generator (not shown), and acord-to-pad interface 504 operatively coupled to a distal end thereof.In accordance with the present disclosure, it is envisioned thatcord-to-pad interface 504 is made of an electrically conductive magneticmaterial. Accordingly, when cord-to-pad interface 504 is approximatedtoward or brought into contact with conductive pad surface 130 of returnpad 120, interface 504 will magnetically couple with conductive padsurface 130. As such, the contact between cord-to-pad interface 504 andconductive pad surface 130 will return energy during electrosurgicalprocedures, from return pad 120 to the electrosurgical generator (notshown).

Turning now to FIG. 8, return pad cable connector 500 includes aconductive return wire cable 502, operatively coupled at a proximal endthereof to an electrosurgical generator (not shown), and a cord-to-padinterface 510 operatively coupled to a distal end thereof. In accordancewith the present embodiment, cord-to-pad interface 510 includes amagnetic substrate 512 having at least one electrical contact 514disposed thereon, wherein wire cable 502 is electrically coupled toelectrical contact(s) 514. It is envisioned that magnetic substrate 512can be made from either conductive or non-conductive materials.Accordingly, when cord-to-pad interface 510 is approximated toward orbrought into contact with conductive pad surface 130 of return pad 120,such that the at least one electrical contact 514 will be brought intocontact with conductive pad surface 130, interface 510 will magneticallycouple with conductive pad surface 130. As such, the contact betweencord-to-pad interface 510 and conductive pad surface 130 will returnenergy during electrosurgical procedures, from return pad 120 to theelectrosurgical generator (not shown).

Turning now to FIG. 9, return pad cable connector 500 includes aconductive return wire cable 502, operatively coupled at a proximal endthereof to an electrosurgical generator (not shown), and a cord-to-padinterface 520 operatively coupled to a distal end thereof. Cord-to-padinterface 520 includes a flexible substrate 522 having a first portion524 and a second portion 526 integrally connected to first portion 524to thereby define a fold line 528. Cord-to-pad interface 520 furtherincludes an electrically conductive magnet 530 provided on each of firstand second portions 524, 526 of substrate 522, wherein wire cable 502 iselectrically coupled to one of the pair of magnets 530. While a pair ofelectrically conductive magnets 530 is disclosed, it is contemplatedthat only magnet 530, which is electrically coupled to wire cable 502,needs to be made from an electrically conductive material while theother magnet can be made from non-conductive materials. It is furtherenvisioned that, if both magnets 530 are non-conductive, an electricalcontact (not shown) can be disposed on magnet 530 which is electricalcontact is electrically coupled to wire cable 502.

As seen in FIG. 9, wire cable 502 can extend from return pad cableconnector 500 from a side of substrate 522 which is parallel to foldline 528, or in the alternative, as shown in phantom, wire cable 502 canextend from return pad cable connector 500 from a side of substrate 522which is transverse to fold line 528.

Use of return pad cable connector 500, shown in FIG. 9, requires thatafter conductive pad surface 130 of return pad 120 is brought intocontact with magnet 530 with is electrically coupled to wire cable 502,flexible substrate 522 is folded along fold line 528 in order toapproximate magnets 530 of first and second portions 524, 526 toward oneanother thereby sandwiching conductive pad surface 130 therebetween. Assuch, the contact between magnet 530, coupled to wire cable 502, andconductive pad surface 130 will return energy during electrosurgicalprocedures, from return pad 120 to the electrosurgical generator (notshown).

As seen in FIG. 10, a preferred method of coupling a magnet to asubstrate for a return pad cable connector 500 is illustrated. Inparticular, a magnet 540 overlies a substrate 542 and at least oneretaining device 544 (i.e., a pin) is used to pass though magnet 540 andimbedded in substrate 542 to secure magnet 540 to substrate 542.Further, as seen in FIG. 10, wire cable 502 can be disposed betweenmagnet 540 and substrate 542. While a pin has been disclosed it isenvisioned that other methods of coupling the magnet to a substrate canbe used, such as, for example, an adhesive, screws, clips, clamps andthe like.

The use of magnets in return pad cable connector 500 results in easierattachment and removal of return pad cable connector 500 from conductivepad surface 130 of return pad 120 as well as easier cleaning of thecontact surfaces and a lower profile.

In accordance with the present disclosure, it is envisioned that returnpad cable connector 500 can be used in combination with a conductiveadhesive disposed between return pad cable connector 500 and conductivepad surface 130.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Therefore, the abovedescription should not be construed as limiting, but merely asexemplifications of preferred embodiments.

What is claimed is:
 1. A return pad cable connector for use with adisposable return pad, comprising: a cord having a conductive wiredisposed therethrough which is connected to an electrosurgical energysource; a connector is operatively coupled to the cord having: aconductive surface selectively engageable with a correspondingconductive surface disposed on the return pad, the conductive surface ofthe connector including a conductive adhesive disposed thereon; and anon-conductive adhesive disposed about the periphery of the conductivesurface of the connector for engagement with a correspondingnon-conductive adhesive disposed on a portion of the conductive surfaceof the return pad.
 2. A return pad cable connector for use with adisposable return pad, comprising: a cord having a conductive wiredisposed therethrough which is connected to an electrosurgical energysource; a connector is operatively coupled to the cord having aconductive surface which is selectively engageable with a correspondingconductive surface disposed on the return pad; and an adhesive providedon at least one of the connector and the return pad to secure theconnector to the return pad.
 3. The return pad cable connector accordingto claim 2, wherein the connector includes at least one conductivesurface which correspondingly mates with at least one conductive surfaceon the return pad, the conductive surface of the connector including aborder therearound for engaging a border around the conductive surfaceof the return pad, wherein the adhesive is provided on at least one ofthe conductive surface of the connector, the conductive surface of thereturn pad, the border surrounding the conductive surface of theconnector and the border surrounding the conductive surface of thereturn pad.
 4. The return pad cable connector according to claim 2,wherein at least the adhesive provided on the conductive surface of thereturn pad is a conductive adhesive.